Reinforcement structure

ABSTRACT

A structural reinforcement comprising a base reinforcing structure including a plurality of ribs and having a first surface and a second surface, an expandable adhesive material located onto a first portion of the first surface, and a sealant material located around an edge of the second surface, the second surface being substantially free of any of the plurality of ribs.

This application claims the benefit of the priority date U.S.Provisional Application Ser. No. 62/365,140, filed Jul. 21, 2016, thecontents of that application being hereby incorporated by referenceherein for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to reinforcement of structures,and more particularly to reinforcement of vehicle structures usingstructural reinforcements with associated adhesives and sealants.

BACKGROUND OF THE INVENTION

In various locations throughout transportation vehicles, recent yearshave seen the increased use of structural reinforcements in whichvehicle cavities are commonly fitted with structural reinforcements thataid in controlling deformation from an impact. For some applications, ithas become popular in recent years to employ a carrier structure incombination with a secondary material, such as an expandable adhesivematerial as part of the reinforcement. See e.g., U.S. Pat. Nos.6,932,421; 6,921,130; 6,920,693; 6,890,021; and 6,467,834 allincorporated by reference. Often, these structures are manufacturedusing injection molding and/or co-extrusion processes.

However, the remains a need for structural reinforcements that includemultiple differing secondary materials and/or attachments while stillmaintaining minimal cycle time during manufacturing.

SUMMARY OF THE INVENTION

The present teachings meet one or more of the above needs by theimproved devices and methods described herein.

In one aspect, the present teachings pertain to a structuralreinforcement comprising a base reinforcing structure including aplurality of ribs and having a first surface and a second surface, anexpandable adhesive material located onto a first portion of the firstsurface, and a sealant material located around an edge of the secondsurface, the second surface being substantially free of any of theplurality of ribs.

The expandable adhesive material and sealant material may be free of anydirect contact with one another in the green state. The expandableadhesive material and sealant material may be free of any direct contactwith one another post-activation. The expandable adhesive material andsealant material may make direct contact with one another duringactivation. The second surface may include a substantially flat portion.The first portion may be substantially free of any sealant material. Thesecond portion may be substantially free of any structural adhesivematerial. The first portion may be arranged such that it is in a planethat lies substantially perpendicular to the plane of the secondportion. The sealant material may be located along an edge of the secondportion that is arranged adjacent to the first portion. The structuraladhesive material have a higher expansion rate during activation thanthe sealant material. The sealant material have a higher expansion rateduring activation than the structural adhesive material.

The teachings herein further provide for a method comprising locating apolymeric material in a mold to form a base reinforcing structureincluding a first portion and a second portion, molding an expandableadhesive material onto the base reinforcing structure, removing the basereinforcing structure and adhesive material from the mold, and extrudinga sealant material onto an edge of the base reinforcing structure,wherein the sealant material is located onto the second portion of thebase reinforcing structure that is substantially free of any adhesivematerial.

The sealant material may be extruded via a mini-applicator. Theexpandable adhesive material and sealant material may be applied so thatthey are substantially free of any direct contact with one another inthe green state. The expandable adhesive material and sealant materialmay be applied so that they are free of any direct contact with oneanother post-activation. The expandable adhesive material and sealantmaterial may be applied so that they make direct contact with oneanother during activation. The second surface may be molded to include asubstantially flat portion. No sealant material may be applied to thefirst portion. No structural adhesive material may be molded onto thesecond portion. The first portion may be molded such that it is in aplane that lies substantially perpendicular to the plane of the secondportion. The sealant material may be extruded along an edge of thesecond portion that is arranged adjacent to the first portion.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an illustrative reinforcement inaccordance with the present teachings.

FIG. 2 is a perspective view of the reinforcement of FIG. 1.

FIG. 3 is a perspective view of the reinforcement of FIG. 1.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. The specific embodiments of the presentinvention as set forth are not intended as being exhaustive or limitingof the invention. The scope of the invention should be determined withreference to the appended claims, along with the full scope ofequivalents to which such claims are entitled. The disclosures of allarticles and references, including patent applications and publications,are incorporated by reference for all purposes. Other combinations arealso possible as will be gleaned from the following claims, which arealso hereby incorporated by reference into this written description.

The invention herein contemplates a unique approach for providing astructural reinforcement that carries at least two different secondarymaterials.

The base reinforcing structure may be formed of a moldable material,which may be a polymeric material, which may be a nylon material. Thebase reinforcing material may be formed by pultrusion. The polymericmaterial may be a reinforced polymeric material. For example, thepolymeric material may be a glass fiber reinforced nylon. The polymericmaterial may be a polyurethane. The polymeric material may be athermoset material. The polymeric material may be a thermoplasticmaterial. The polymeric material may be a thermoplastic epoxy material.The polymeric material may be a fiber reinforced thermoplastic epoxymaterial.

The adhesive material and/or sealant material may be a material thatexperiences expansion and/or cure upon exposures to temperatures ofbetween about 148.89° C. to about 204.44° C. (about 300° F. to about400° F.) (i.e., temperatures typically experienced in automotivepainting or coating operations). The adhesive material and/or materialmay be foamed to a volume of at least 5% greater, at least 50% greater,at least 200% greater, at least 1000% greater, at least 2000% greater,at least 5000% greater or higher relative to the original unexpandedvolume.

The adhesive and/or sealant material may be an epoxy based material suchas those disclosed in U.S. Pat. Nos. 5,884,960; 6,348,513; 6,368,438;6,811,864; 7,125,461; 7,249,415; and U.S. Patent Publication No.2004/0076831, hereby incorporated by reference.

The adhesive materials and sealant materials may include an epoxy resincomponent. Epoxy resin is used herein to mean any of the conventionalepoxy materials containing at least one epoxy functional group. Theepoxy resins can be difunctional, trifunctional, multifunctional,combinations thereof or otherwise. Moreover, the term epoxy resin can beused to denote one epoxy resin or a combination of epoxy resins. Thepolymer-based materials may be epoxy-containing materials having one ormore oxirane rings polymerizable by a ring opening reaction. Inpreferred embodiments, the adhesive and/or sealant material of thisinvention includes between about 2% and 70% by weight epoxy resin, morepreferably between about 7% and 50% by weight epoxy resin and even morepreferably between about 15% and 40% by weight epoxy resin and evenpossibly between about 15% and about 25% by weight epoxy resin.

The epoxy may be aliphatic, cycloaliphatic, or aromatic. The epoxy maybe supplied as a solid (e.g., as pellets, chunks, pieces or the like) ora liquid (e.g., an epoxy resin) or both. As used herein, a resin isconsidered to be a solid resin if it is solid at a temperature of 23° C.and is considered to be a liquid resin if it a liquid at 23° C. Thepresence of the epoxy resin increases the adhesion, flow properties, orboth of the adhesive and/or sealant. One exemplary epoxy resin may be aphenolic resin, which may be a novalac type or other type resin. Forexample, bisphenol A resin, bisphenol F resin, a combination thereof orthe like may be employed. Moreover, various mixtures of severaldifferent epoxy resins may be employed. Examples of suitable epoxyresins are sold under the tradename DER® (e.g., DER 331, DER 661, DER662), commercially available from the Dow Chemical Company, Midland,Mich.

Liquid epoxy resins may be utilized. Such resins may be utilized toreduce the overall viscosity of the adhesive or sealant. Liquid epoxyresins that may be used typically have a viscosity at a temperature of23° C. of at least 5000, more typically at least 8000 and even possiblyat least 11,000 cps, but typically less than 30,000, more typically lessthan 22,000 and even possibly less than 15,000 cps, although higher andlower values may also be possible unless otherwise stated. The liquidepoxy resin typically has an epoxy equivalent weight of at least 80,more typically at least 150 and even possibly at least 185 g/eq, buttypically less than 300, more typically less than 220 and even possiblyless than 195 g/eq, although higher and lower values may also bepossible unless otherwise stated. Preferred liquid resins includediglycidyl ethers that may be aromatic phenol based (bisphenol A or F)and are sold under the tradename DER 331, commercially available fromthe Dow Chemical Company and EPON 828 and EPON 863, commerciallyavailable from Hexion Specialty Chemicals.

In the preferred embodiment the epoxy resins used are such that theformulated adhesive and sealant are dry to the touch at ambienttemperature.

Additional polymeric materials may be utilized. As one example, one ormore thermoplastic modifiers such as polyethers which include pendanthydroxyl moieties. Particularly desirable thermoplastic polyethers arephenoxy resins. As used herein, phenoxy resin is a polyhydroxyether,with ether linkages along the polymer backbone and pendant hydroxylgroups. One useful phenoxy resin is the reaction product of a phenolbased difunctional epoxy resin and a difunctional phenol (for examplethe reaction product of bisphenol A epoxy with bisphenol A). A similarmaterial may also be synthesized directly from a bisphenol (for examplebisphenol A) and epichlorohydrin. The terminal epoxy group may be ringopened to generate a terminal alpha glycol group. The phenoxy resinshave weight-average molecular weights of at least about 5,000, moretypically at least about 25,000 and still more typically at least about50,000 but less than about 100,000, more typically less than about75,000 and still more typically less than about 60,000. Otherthermoplastic polyethers include aromatic ether/amine repeating units intheir backbones such as polyetheramines, poly(amino ethers), copolymersof monoethanolamine and diglycidyl ether, combinations thereof or thelike. Examples of thermoplastic polyethers are disclosed in U.S. Pat.Nos. 5,275,853; 5,464,924 and 5,962,093. The thermoplastic modifierssuch as the polyethers preferably comprise between 3% and about 40% byweight of the adhesive or sealant material and even more preferablybetween about 10% and 30% more preferably between 10% and about 15%.

Several additional polymers may be incorporated into the adhesive and/orsealant material, e.g., by copolymerization, by blending, or otherwise.For example, without limitation, other polymers that might beappropriately incorporated into the sealant material include halogenatedpolymers, polycarbonates, polyketones, urethanes, polyesters, silanes,sulfones, allyls, olefins, styrenes, acetates, ethylene vinyl acetates,acrylates, methacrylates, epoxies, silicones, phenolics, rubbers,polyphenylene oxides, terphthalates, or mixtures thereof. Otherpotential polymeric materials may be or may include, without limitation,polyethylene, polypropylene, polystyrene, polyolefin, polyacrylate,poly(ethylene oxide), poly(ethyleneimine), polyester, polyurethane,polysiloxane, polyether, polyphosphazine, polyimide, polyimide,polyisobutylene, polyacrylonitrile, poly(vinyl chloride),poly(methylmethacrylate), poly(vinyl acetate), poly(vinylidenechloride), polytetrafluoroethylene, polyisoprene, polyacrylamide,polyacrylic acid, polymethacrylate, and polyacetals.

It is possible that the adhesive and/or sealant material includes anacrylate copolymer, acetate copolymer or both. The adhesive and/orsealant material may include ethylene methyl acrylate (EMA), ethylenevinyl acetate (EVA) or a combination thereof. When included, EMA istypically between about 1% and about 70%, more typically between about30% and about 60% and even more typically between about 44% and about55% by weight of the adhesive and/or sealant material. A desirable EMAcan have a melt index between about 110 and about 150 grams/10 min.(e.g., about 135 grams/10 min.). One preferred EMA is sold under thetradename TC140 and is commercially available from Exxon. When included,EVA is typically between about 1% and about 70%, more typically betweenabout 2% and about 10% and even more typically between about 3% andabout 5% by weight of the melt flow material.

It is also contemplated that the adhesive and/or sealant material caninclude one or more isocyanate reactive ingredients (e.g., polyols),which can be reactive with blocked isocyanates. Example of suchingredients and isocyanates are disclosed in U.S. Patent Application,Publication No. 2005/0320027, which is incorporated herein by referencefor all purposes.

The adhesive and/or sealant material may include one or more additionalpolymers (e.g., copolymers), which are typically, but not necessarilycopolymers or terpolymers, which can include a variety of differentpolymers, such as thermoplastics, elastomers, thermosets,thermosettables combinations thereof or the like. For example, andwithout limitation, polymers that might be appropriately incorporatedinto the adhesive and/or sealant material include halogenated polymers,polycarbonates, polyketones, and polymers of urethanes, polyesters,silanes, sulfones, allyls, olefins, styrenes, acrylates, methacrylates,epoxies, silicones, phenolics, rubbers, polyphenylene oxides,terphthalates, acetates (e.g., EVA), acrylates, methacrylates (e.g.,ethylene methyl acrylate polymer) or mixtures thereof. Other potentialpolymeric materials may be or may include, without limitation,polyolefin (e.g., polyethylene, polypropylene) polystyrene,polyacrylate, polyethylene oxide), poly(ethyleneimine), polyester,polyurethane, polysiloxane, polyether, polyphosphazine, polyimide,polyimide, polyisobutylene, polyacrylonitrile, polyvinyl chloride),poly(methyl methacrylate), polyvinyl acetate), poly(vinylidenechloride), polytetrafluoroethylene, polyisoprene, polyacrylamide,polyacrylic acid, polymethacrylate. Although not required, it may bedesired for the adhesive and/or sealant material to include one or moreethylene polymers or copolymers such as ethylene acrylates, ethyleneacetates, or the like. Ethylene methacrylate and ethylene vinyl acetateare two preferred ethylene copolymers. When used, the one or moreadditional polymers comprises about 0.1% to about 50%, more preferablyabout 1% to about 20% and even more preferably about 5% to about 15% byweight of the adhesive and/or sealant material.

The adhesive and/or sealant material can also include one or morematerials for controlling the rheological characteristics of the sealantmaterial over a range of temperatures (e.g., up to about 250° C. orgreater). Any suitable art-disclosed rheology modifier may be used, andthus the rheology modifier may be organic or inorganic, liquid or solid,or otherwise. The rheology modifier may be a polymer, and morepreferably one based upon an olefinic (e.g., an ethylene, a butylenes, apropylene or the like), a styrenic (e.g., a styrene-butadiene-containingrubber), an acrylic or an unsaturated carboxylic acid or its ester (suchas acrylates, methacrylates or mixtures thereof; e.g., ethylene methylacrylate (EMA) polymer) or acetates (e.g., EVA). The rheology modifiermay be provided in a generally homogeneous state or suitable compoundedwith other ingredients. It is also contemplated that the various clays,minerals or other materials discussed in relation to fillers below canbe employed to modify rheology of the adhesive and/or sealant material.

The adhesive and/or sealant material may each include one or more curingagents that assist the adhesive and/or sealant material in curing bycrosslinking of the polymers, epoxy resins and other ingredients in thematerial. The amount of curing agents or curing agent acceleratorspresent in the adhesive and/or sealant material range from about 0.001%by weight to about 9% by weight and more typically from about 0.2 toabout 6 wt %, and even more typically from about 2 wt % to about 6% byweight. The curing agent materials can be selected from aliphatic oraromatic amines or their respective adducts, amidoamines, polyamides,cycloaliphatic amines, anhydrides, polycarboxylic polyesters,isocyanates, phenol-based resins (e.g., phenol or cresol novolak resins,copolymers such as those of phenol terpene, polyvinyl phenol, orbisphenol-A formaldehyde copolymers, bishydroxyphenyl alkanes or thelike), dihydrazides, sulfonamides, diamino diphenyl solfone, anhydrides,mercaptans, imidazoles, ureas, tertiary amines, BF3 complexes ormixtures thereof. Particular preferred curing agents include modifiedand unmodified polyamines or polyamides such as triethylenetetramine,diethylenetriamine tetraethylenepentamine, cyanoguanidine,dicyandiamides and the like.

An accelerator for the curing agents (e.g., a modified or unmodifiedurea such as methylene diphenyl bis urea, an imidazole, blocked amine ora combination thereof) may also be provided for preparing the adhesiveand/or sealant material.

The adhesive and/or sealant materials may contain other additives suchas flexibilizers, impact modifiers, polymers or copolymers fillers andother elongation promoting additives.

If included, such impact modifiers (e.g., toughening agents) contributeto the desired mechanical properties of the adhesive and/or sealantmaterial such as Lap Shear and T Peel strength by the distribution ofenergy within the adhesive and/or sealant system. It is generallypreferable for the impact modifier to be at least 4%, more typically at10%, and even more typically at least 20% by weight of the adhesiveand/or sealant material and also preferable for the impact modifier tobe less than 70%, more typically less than 40% an even more typicallyless than 30% by weight of the adhesive and/or sealant material. Theterm “impact modifier” can include one impact modifier or several impactmodifiers. The impact modifier can include thermoplastics, thermosets orthermosettables, elastomers, combinations thereof or the like. In apreferred embodiment the impact modifier includes elastomer (includingelastomer containing materials), a core/shell polymer (which may includeelastomer), or a combination thereof.

The impact modifier may include a substantial portion of core/shellimpact modifier. When it includes a core/shell polymer it is preferredthat the impact modifier is comprised of at least 60%, more typically atleast 80% and even possibly at least 97% core/shell polymer. As usedherein, the term core/shell impact modifier denotes an impact modifierwherein a substantial portion (e.g., greater than 30%, 50%, 70% or moreby weight) thereof is comprised of a first polymeric material (i.e., thefirst or core material) that is substantially entirely encapsulated by asecond polymeric material (i.e., the second or shell material). Thefirst and second polymeric materials, as used herein, can be comprisedof one, two, three or more polymers that are combined and/or reactedtogether (e.g., sequentially polymerized) or may be part of separate orthe same core/shell systems.

The first and second polymeric materials of the core/shell impactmodifier can include elastomers, polymers, thermoplastics, copolymers,other components, combinations thereof or the like. In preferredembodiments, the first polymeric material, the second polymeric materialor both of the core/shell impact modifier include or are substantiallyentirely composed of (e.g., at least 70%, 80%, 90% or more by weight)one or more thermoplastics. Exemplary thermoplastics include, withoutlimitation, poly-styrenics, poly-acrylonitriles, poly-acrylates,poly-acetates, polyamides, and poly-olefins.

Preferred core/shell impact modifiers are formed by emulsionpolymerization followed by coagulation or spray drying. In certainapplications, coagulated grades of core/shell impact modifiers have beenfound particularly desirable for promoting adhesion to surfaces havingimpurities thereon such as dirt, oil (e.g., metal stamping oil) or thelike. Such impact modifiers can reduce the likelihood of adhesivefailure (as opposed to cohesive failure).

Examples of useful core-shell graft copolymers that may be used asimpact-modifiers are those where hard containing compounds, such asstyrene, acrylonitrile or methyl methacrylate, are grafted onto a coremade from polymers of soft or elastomeric containing compounds such asbutadiene or butyl acrylate. U.S. Pat. No. 3,985,703, describes usefulcore-shell polymers, the core polymers of which are made from butylacrylate but can be based on ethyl isobutyl, 2-ethylhexyl or other alkylacrylates or mixtures thereof. The core polymer may also include othercopolymerizable containing compounds, such as styrene, vinyl acetate,methyl methacrylate, butadiene, isoprene, or the like. The core polymermaterial may also include a cross linking monomer having two or morenonconjugated double bonds of approximately equal reactivity such asethylene glycol diacrylate, butylene glycol dimethacrylate, and thelike. The core polymer material may also include a graft linking monomerhaving two or more nonconjugated double bonds of unequal reactivity suchas, for example, diallyl maleate and allyl methacrylate.

The shell portion may be polymerized from methyl methacrylate andoptionally other alkyl methacrylates, such as ethyl and butylmethacrylates or mixtures thereof. Up to 40 percent by weight or more ofthe shell monomers may be styrene, vinyl acetate, vinyl chloride, andthe like. Additional core-shell graft copolymers useful in embodimentsof the present invention are described in U.S. Pat. Nos. 3,984,497;4,096,202; 4,034,013; 3,944,631; 4,306,040; 4,495,324; 4,304,709; and4,536,436. Examples of core-shell graft copolymers include, but are notlimited to, “MBS” (methacrylate-butadiene-styrene) polymers, which aremade by polymerizing methyl methacrylate in the presence ofpolybutadiene or a polybutadiene copolymer rubber. The MBS graftcopolymer resin generally has a styrene butadiene rubber core and ashell of acrylic polymer or copolymer. Examples of other usefulcore-shell graft copolymer resins include, ABS(acrylonitrile-butadiene-styrene), MABS(methacrylate-acrylonitrile-butadiene-styrene), ASA(acrylate-styrene-acrylonitrile), all acrylics, SA EPDM(styrene-acrylonitrile grafted onto elastomeric backbones ofethylene-propylene diene monomer), MAS (methacrylic-acrylic rubberstyrene), and the like and mixtures thereof.

The adhesive and/or sealant composition may be activatable (e.g.,foamable) and as such it may contain one or more foaming agents thattypically produce inert gasses that transform the adhesive/sealant intoan open and/or closed cellular structure. The expansion can help toimprove adhesion, sealing capability, acoustic damping, reduce density,or a combination of factors. Amounts of blowing agents and blowing agentaccelerators that can be used can vary widely depending upon the type ofcellular structure desired, the desired amount of expansion of theadhesive and/or sealant material, the melt viscosity of the materials,and the desired rate of expansion. Exemplary ranges for the amounts ofblowing agents and blowing agent accelerators in the activatablematerial range from about 0.001% by weight to 2%.

Chemical blowing agents that may be used include one or more nitrogencontaining groups such as amides, amines, and the like. Examples ofsuitable blowing agents include dinitrosopentamethylenetetramine,azodicarbonamide, dinitrosopentamethylenetetramine,4,4′oxy-bis-(benzene-sulphonylhydrazide), trihydrazinotriazine andN,N′-dimethyl-N,N′-dinitroso-terephthalamide.

Physical blowing agents may additionally or alternatively be employed.As one example, solvent filled polymeric shells that soften and expandupon exposure to heat may be used. A typical example is sold under thetrade name Expancel by Akzo Nobel.

An accelerator for the chemical blowing agents may also be provided inthe adhesive and/or sealant material to increase the rate at which theblowing agents form inert gasses. One preferred blowing agentaccelerator is a metal salt, such as an oxide, for example zinc oxide.Other preferred accelerators include organic bases such as urea andorganic acids such as adipic or benzoic acid. Zinc benzene sulfonate mayalso be a desirable accelerator.

The adhesive and/or sealant material of the present invention may alsoinclude one or more fillers, including but not limited to particulatematerials (e.g., powder), beads, microspheres, or the like. Use offillers can impart properties such as strength, dimensional stability,and impact resistance to the adhesive and/or sealant they can howeverreduce elongation properties. Filler addition can also reduceformulation cost and produce products that have less tack prior to cure.

Examples of fillers that may be used include silica, diatomaceous earth,glass, clay (e.g., including nanoclay), talc, pigments, colorants, glassbeads or bubbles, carbon or ceramic fibres and nylon or polyamide fibres(e.g., Kevlar). Examples of suitable fillers include, withoutlimitation, wollastonite, talc, vermiculite, pyrophyllite, sauconite,saponite, nontronite, montmorillonite or mixtures thereof. Clays usablefor the adhesive and/or sealant material may be calcined or uncalcined.Clays that may be used as fillers may include clays from the kaolinite,illite, chloritem, smecitite or sepiolite groups, which may be calcined.The clays may also include minor amounts of other ingredients such ascarbonates, feldspars, micas and quartz. One or more mineral or stonetype fillers such as calcium carbonate, sodium carbonate or the like maybe used as fillers. Silicate minerals such as mica may be used asfillers.

When employed, the amount of fillers in the adhesive and/or sealantmaterial can range from 2% to more than 30% or greater by weight, butmore typical from about 8 to 25% by weight, however amounts (below 20%)are preferable in order to retain the desired elongation of the adhesiveand/or sealant. According to some embodiments, the adhesive and/orsealant material may include from about 0% to about 3% by weight, andmore preferably slightly less than 1% by weight clays or similarfillers. Powdered (e.g. about 0.01 to about 50, and more preferablyabout 1 to 25 micron mean particle diameter) mineral type filler cancomprise between about 5% and 40% by weight, more preferably about 10%to about 25% by weight.

The adhesives and sealants described herein may be a liquid, a paste ora solid. It is possible that the adhesive and/or sealant material isformed as a material that is solid at ambient temperature, is non tackyto the touch and has a substantially homogeneous composition. Variousmixing techniques may be used to obtain such a material.

According to one embodiment, the adhesive material may be formed byheating one or more of the components that are generally easier tosoften or liquidize such as the polymer based materials to induce thosecomponents into a mixable state. Thereafter, the remaining componentsmay then be intermixed with the softened components.

It is also possible that the materials are provided individually, asadmixtures or combinations thereof to an extruder. The extruder thenmixes the materials to form the adhesive and/or sealant material.Alternatively the adhesive and/or sealant material may be fully mixedand formed and then fed to an extruder for dispensing.

As shown for example in FIGS. 1-3, the reinforcement structure 10 isshown having a base reinforcing structure 12 having a first surface 13 aand a second surface 13 b, an adhesive material 14 located on the firstsurface 13 a and a sealant material 16 located onto an edge, which maybe about the periphery, of the second surface 13 b. The first surfacemay include a plurality of rib structures 20. The second surface mayinclude a substantially flat portion 18. The flat portion 18 is shown inthe figures as being substantially free of any adhesive material 14. Therib structures 20 are shown in the figures as being substantially freeof any sealant material 16.

The reinforcement structure may be formed by a combination of moldingsteps and extrusion steps. The base reinforcing structure may be formedby an injection molding step. The adhesive material may be applied tothe base reinforcing structure by a second molding process (e.g., atwo-shot molding process) whereby the adhesive material is injectionmolded onto the base reinforcing structure. The sealant material maythen be extruded onto the base reinforcing structure. The extrusionprocess may be completed by a traditional twin screw extruder, or may beextruded by a robotic extrusion system, including a mini applicator(e.g., mini extruder) attached to a robotic arm. The base reinforcingstructure may thus be removed from a molding device (such removal may beautomated) and moved in-line to a location where the sealant material isextruded onto a portion of the base reinforcing structure.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the invention. The scope of the inventionshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

What is claimed is:
 1. A structural reinforcement comprising: i) a basereinforcing structure including a plurality of ribs and having a firstsurface and a second surface; ii) an expandable adhesive materiallocated onto a first portion of the first surface; iii) a sealantmaterial located around an edge of the second surface, the secondsurface being substantially free of any of the plurality of ribs.
 2. Thestructural reinforcement of claim 1, wherein the expandable adhesivematerial and sealant material are free of any direct contact with oneanother in the green state.
 3. The structural reinforcement of claim 2,wherein the expandable adhesive material and sealant material are freeof any direct contact with one another post-activation.
 4. Thestructural reinforcement of claim 2, wherein the expandable adhesivematerial and sealant material make direct contact with one anotherduring activation.
 5. The structural reinforcement of claim 1, whereinthe second surface includes a substantially flat portion.
 6. Thestructural reinforcement of claim 1, wherein the first portion issubstantially free of any sealant material.
 7. The structuralreinforcement of claim 1, wherein the second portion is substantiallyfree of any structural adhesive material.
 8. The structuralreinforcement of claim 2, wherein the first portion is arranged suchthat it is in a plane that lies substantially perpendicular to the planeof the second portion.
 9. The structural reinforcement of claim 5,wherein the sealant material is located along an edge of the secondportion that is arranged adjacent to the first portion.
 10. Thestructural reinforcement of claim 1, wherein the structural adhesivematerial has a higher expansion rate during activation than the sealantmaterial.
 11. A method comprising: locating a polymeric material in amold to form a base reinforcing structure including a first portion anda second portion; molding an expandable adhesive material onto the basereinforcing structure; removing the base reinforcing structure andadhesive material from the mold; extruding a sealant material onto anedge of the base reinforcing structure, wherein the sealant material islocated onto the second portion of the base reinforcing structure thatis substantially free of any adhesive material.
 12. The method of claim11, wherein the sealant material is extruded via a mini-applicator. 13.The method of claim 11, wherein the expandable adhesive material andsealant material are applied so that they are substantially free of anydirect contact with one another in the green state.
 14. The method ofclaim 12, wherein the expandable adhesive material and sealant materialare applied so that they are free of any direct contact with one anotherpost-activation.
 15. The method of claim 12, wherein the expandableadhesive material and sealant material are applied so that they makedirect contact with one another during activation.
 16. The method ofclaim 11, wherein the second surface is molded to include asubstantially flat portion.
 17. The method of claim 11, wherein nosealant material is applied to the first portion.
 18. The method ofclaim 13, wherein no structural adhesive material is molded onto thesecond portion
 19. The method of claim 11, wherein the first portion ismolded such that it is in a plane that lies substantially perpendicularto the plane of the second portion.
 20. The method of claim 11, whereinthe sealant material is extruded along an edge of the second portionthat is arranged adjacent to the first portion.